Contact plug assembly apparatus



May 21, 1963 w. P. HERMAN 3,090,111

CONTACT PLUG ASSEMBLY APPARATUS Filed Dec. 21, 1959 4 Sheets-Sheet 1 IN V EN TOR.

VgLLLIAM P. HERMAN- ATTORNEY y 1, 1963 w. P. HERMAN 3,090,111

CONTACT PLUG ASSEMBLY APPARATUS 4 Sheets-Sheet 2 Filed Dec. 21, 1959 i a f 45 IN V EN TOR.

ATTORN May 21, 1963 w. P. HERMAN 3,0

CONTACT PLUG ASSEMBLY APPARATUS Filed D60. 21, 1959 4 Sheets-Sheet 3 FIG.5

56 53 39 JUN-1 [:IIIHIH I 38 329 5/ 33 V 48 v /Q FIG? FIG.8

1N VEN TOR.

WILLIAM P. HERMAN May 21, 1963 w. P. HERMAN 3,090,111

CONTACT PLUG ASSEMBLY APPARATUS Filed Dec. 21, 1959 4 SheetsSheet 4 Y uvmvrox WILLIAM P. HERMAN United States Patent 3,090,111 CONTACT PLUG ASSEMBLY APPARATUS William P. Herman, Providence, R.I., assignor, by mesne assignments, to North American Philips Company, Inc., New York, N.Y., a corporation of Delaware Filed Dec. 21, 1959, Ser. No. 861,136 9 Claims. (Cl. 29-206) My present invention relates to the manufacture of electrical contact plugs, and has particular reference to a novel apparatus for assembling the electrical contact blades and cord lead wires within the plug husk.

The present application is an improvement on my patents entitled, Connector Plug Assembly Apparatus, No. 2,198,966, issued April 30, 1940, and Apparatus for Assembly of Connector Plugs, No. 2,278,176, issued March 31, 1942.

The principal object of the present invention is to provide an apparatus for inserting a set of electrical contact blades, with cord lead wires attached, into a plug husk.

Another object of the present invention is to provide an assembly apparatus of the type described having a minimum number of parts and operating at low pressure.

A further object of the present invention is to provide an assembly apparatus which is simple in construction and easy and economical to manufacture, assemble and operate.

With the above and other objects and advantageous features in view, my invention consists of a novel arrangement of parts, more fully described in the detailed description following in conjunction with the accompanying drawings and more particularly defined in the appended claims.

In the drawings,

FIG. 1 is a plan view of an assembly machine embodying my invention.

FIG. 2 is the side elevation thereof.

FIG. 3 is a longitudinal section thereof.

FIG. 4 is a section taken on line 44 on FIG. 3.

FIG. 5 is a front view thereof.

FIG. 6 is a rear view thereof.

FIG. 7 is a section taken on line 77 on FIG. 3.

FIG. 8 is a section taken on line 88 on FIG. 3.

FIGS. 9, 10 and 11 are detailed views showing the assembly operation.

FIG. 12 is a perspective view of the assembled plug.

In my patents herein referred to, I have described an apparatus for assembling contact blades with plug husks. For example, referring to FIG. 12, the contact plug shown therein comprises a soft rubber plug husk 20 preferably made of an integral one-piece body of resilient mate rial and provided with a pair of spaced contact blades 21 and electrical cord connection 22. The apparatus referred to spreads the plug husk 20, passes a pair of finders or pull arms through the plug husk and pulls the contact blades and cord lead assembly into the plug husk. The apparatus referred to was operated by compressed air and the blades necessary for carrying out the various steps of the assembly required a pressure of at least 100 pounds. The present invention provides an apparatus for accomplishing the same assembly operation at higher speeds and with reduced pressures. The present apparatus is designed to eliminate many of the moving parts heretofor used and to provide a simplified streamlined machine.

Referring more in detail to the drawings, the apparatus includes a lower casing or housing 23 which houses the actuating mechanism and upon which the assembly parts are mounted. The housing 23 is provided with a central longitudinal bore 24 in which a piston 25 is slidable. The piston 25 is provided at each end with a conventional flex- 3,090,111 Patented May 21, 1963 ible cup 26 held in place by a washer 27 and a bolt 28. While reciprocation may be provided by any suitable means, I prefer to use fluid or air pressure. The apparatus of the present invention will operate at a pressure of as low as 40 pounds to the square inch, but it is preferable that the pressure be between 50 and 60 pounds. Fluid or air inlet means 29 are positioned at each end to reciprocate the piston 25 in the manner disclosed in the patent hereinabove referred to.

Referring to FIG. 3, the piston 25 carries a vertical post or pin 30 which extends upwardly through a slot 31 in the bore 24 and through a slot 32 in the upper part of the casing 23. Reciprocation of the piston 25 causes reciprocating movement of the post or pin 30. The top of the base comprises flat longitudinal plates 33 and 34 spaced from each other to form central rectangular openings 35 and an opening 36 at the forward end. A rectangular block 37 is mounted on the pin 30 which extends into an opening 38 in the block 37. A cover plate 39 is bolted over the top of the block 37. Mounted beneath the block 37 is a tongue or bar 40 extending forwardly and terminating in cam shoulders 41 and forwardly extending tip 42. The bar 40 is lossely mounted in a cut out portion 43 beneath the block 37 as shown in FIG. 7. It is provided with an elongated slot 44 through which the pin 30 extends. During the reciprocation of the pin 30 and the block 37, the slot 44 produces a lost motion effect on the bar 40.

Mounted beneath the bar 40 is a rearwardly extending bar 45 also having a cam shoulder 46 and an elongated tip 47. The bar 45 is immovably attached to the bottom of the block 37 as shown in FIG. 7. With this arrangement, reciprocation of the pin 30 will cause the block 37 to slide between the edges of the plates 33 and 34 as shown in FIG. 7. The bar 45 will move with the block. However, the bar 40 will not move until the pin has first moved from one end of the slot 44 to the other end. The plates 33 and 34 may be independently mounted or may be integral with the base as shown in FIG. 7.

Mounted forwardly on the plates 33 and 34 are a pair of oppositely disposed channel members 48 and 49, one at each side edge as shown in FIGS. 1 and 8. A plate 50 is mounted on a block '51 for limited sliding movement on the base, the outer edges of the block 51 engaging the edges of the members 48 and 49. If desired, a spring 5 2 may be added to retain the plate in rearwardly position. The nest 53 which retains the plug husk 20 is mounted on the plate 50. A guide block 54 is mounted rearwardly on the nest. A pair of pull arms 55 and 56 having hooked ends are mounted on the block 37 and retained in place by the plate 39. The pull arms are mounted to converge toward the ends and pass along the side edges of the guide block 5 4.

Thus forward movement of the block 37 will pass the pull arms 55 and 56 through the nest and through the plug husk 20 mounted therein.

To spread the plug husk 24), the base is provided with a transverse groove 57 in which a pair of blocks 58 and 59 are slidably mounted. The blocks 58 and 59 are resiliently held towards each other by a spring 60 mounted beneath the block between pins 61 extending downwardly from each block. The blocks 58 and 59' are provided with rounded edges 62 in the path of movement of the edge 41 on the bar 40 as shown in FIG. 4. A hook 63 is mounted on each block 5 8 and 59 with the pointed hook ends meeting in the center as shown in FIG. 1.

Mounted on the rear portion of the base is a housing 64 having a flexible air hose 65 connected to a rear opening thereof. A pin 66 is mounted at the front end of a reciprocable piston in the housing 64 and adjusts at 67. A pair of spaced rods 68 and 69 are slidably mounted in parallel relation in the block 3 7 so that the front ends thereof bear against the nest 53. The rear ends of the rods 68 and 69 are connected by a block 79 and the forward end of the pin 66 bears against the block 70 as shown in FIG. 3.

Transversely mounted adjacent the block 7% are a pair of blocks 71 and 72 urged towards each other by a spring 73 mounted beneath the blocks. The blocks 71 and 7-2 are provided with cam shoulders 7 4 in alignment with the shoulders 46 on the bar 45.

A plug husk 20 is placed in the nest 53 as shown in FIG. 9. As the block 37 is reciprocated fonwardly, there will first be a lost motion so that no movement of the bar 40 will take place. However, the bar 45 will move immediately. Simultaneously the pin 66 will push the block 70 forwardly under air pressure causing the rods 68 and 69 to move the nest to a forward position. The cam shoulders 46 on the bar 45 are also moved forwardly and allow the blocks 71 and 72 to spring inwardly behind the block 79 thus looking it in position. Further forward movement of the block 36 will cause the shoulders 41 on the forward end of the bar 40 to engage the shoulders 62 on the blocks 58 and 59 and spread the blocks apart. Shortly after the engagement of the shoulders 4i and 62, and after the blocks 58 and 5? begin to spread, the pull arms will enter the nest area and pass through the husk. This will cause the hooks 63 to move apart. FIG. 10 shows this action with the blades hooked 70. Further rearward movement will then push the block 70 back against the pin 66, and as the pull arms also come back through the plug husk the nest 53 will also be pulled rearwardly. Simultaneously the bar 40 will disengage the blocks 58 and 59 which will slide inwardly, and the hooks 63 will return to the position shown in FIG. 1, see FIG. 11 showing the completed assembly.

The lost motion provided by the slot 44 provides a means of putting the husk under tension before the finders enter the plug. It also provides a means for drawing the contact blades into the foremost position in the plug before the spreaders are closed. Other advantages of the present invention will be readily apparent to a person skilled in the art.

I claim:

1. An apparatus comprising a base, a nest mounted on said base for limited reciprocating movement, said nest being adapted to receive a plug husk of resilient material having an opening, a block mounted for reciprocating movement on said base, pull arms carried by said block and movable through a plug husk positioned in said nest for pulling contact prongs through said plug husk, means for distending the husk opening, means carried by said block for operating the distending means in timed sequence to the movement of said pull arms, fluid operated means for reciprocating said block, and means for reciprocating said nest in timed sequence to the movement of said block, said nest reciprocating means comprising a fluid cylinder mounted at the rear of said base, a pin extending from said cylinder, a second block slidably mounted on said base and actuated by said pin, and connecting rods between said second block and said nest.

2. An apparatus comprising a base, a nest mounted on said base for limited reciprocating movement, said nest being adapted to receive a plug husk of resilient material having an opening, a block mounted for reciprocating movement on said base, pull arms carried by said block and movable through a plug husk positioned in said nest for pulling contact prongs through said plug husk, means for distending the husk opening, means carried by said block for operating the distending means in timed sequence to the movement of said pull arms, fluid operated means for reciprocating said block, and means for reciprocating said nest in timed sequence to the movement of said block, said nest reciprocating means comprising a fluid cylinder mounted at the rear of said base, a pin extending from said cylinder, a second block slidably mounted on said base and actuated by said pin, and connecting rods between said second block and said nest, said connecting rods passing through said first-named block.

3. An apparatus comprising a base, a nest mounted on said base for limited reciprocating movement, said nest being adapted to receive a plug husk of resilient material having an opening, a block mounted for reciprocating movement on said base, pull arms carried by said block and movable through a plug husk positioned in. said nest for pulling contact prongs through said plug husk, means for distending the husk opening, means carried by said block for operating the distending means in timed sequence to the movement of said pull arms, fluid operated means for reciprocating said block, and means for reciprocating said nest in timed sequence to the movement of said block, said distending means comprising a pair of hook members mounted for transverse sliding movement in front of said nest, a cam bar carried by said block for operating said hook members, said block having a vertical pin extending through an opening in said cam bar, said opening being elongated to provide a lost motion effect.

4. An apparatus comprising a base, a nest mounted on said base for limited reciprocating movement, said nest being adapted to receive a plug husk of resilient material having an opening, a block -mounted for reciprocating movement on said base, pull arms carried by said block and movable through a plug husk positioned in said nest for pulling contact prongs through said plug husk, means for distending the husk opening, means carried by said block for operating the distending means in timed sequence to the movement of said pull arms, fluid operated means for reciprocating said block, and means for reciprocating said nest in timed sequence to the movement of said block, said distending means comprising a pair of hook members mounted for transverse sliding movement in front of said nest, a cam bar carried by said block for operating said hook members, said block having a vertical pin extending through an opening in said cam bar, said opening being elongated to provide a lost motion effect, and means for locking said nest in forward position during the forward movement of said block.

5. An apparatus comprising a base, a nest mounted on said base for limited reciprocating movement, said nest being adapted to receive a plughusk of resilient material having an opening, a block mounted for reciprocating movement on said base, pull arms carried by said block and movable through a plug husk positioned in said nest for pulling contact prongs through said plug husk, means for distending the husk opening, means carried by said block for operating the distending means in timed sequence to the movement of said pull arms, fluid operated means for reciprocating said block, and means for reciprocating said nest in timed sequence to the movement of said block, said nest reciprocating means comprising a fluid cylinder mounted at the rear of said base, a pin extending from said cylinder, a second block slidably mounted on said base and actuated by said pin, and connecting rods between said second block and said nest. said distending means comprising a pair of hook members mounted for transverse sliding movement in front of said nest.

6. An apparatus comprising a base, a nest mounted on said base for limited reciprocating movement, said nest being adapted to receive a plug husk of resilient material having an opening. a block mounted for reciprocating movement on said base, pull arms carried by said block and movable through a plug husk positioned in said nest for pulling contact prongs through said plug husk, means for distending the husk opening,

means carried by said block for operating the distending means in timed sequence to the movement of said pull arms, fluid operated means for reciprocating said block, and means for reciprocating said nest in timed sequence to the movement of said block, said nest reciprocating means comprising a fluid cylinder mounted at the rear of said base, a pin extending from said cylinder, a second block slidably mounted on said base and actuated by said pin, and connecting rods between said second block and said nest, said connecting rods passing through said firstnamed block, said distending means comprising a pair of hook members mounted for transverse sliding movement in front of said nest.

7. An apparatus comprising a base, a nest mounted on said base for limited reciprocating movement, said nest being adapted to receive a plug husk of resilient material having an opening, a block mounted for reciprocating movement on said base, pull arms carried by said block and movable through a plug husk positioned in said nest for pulling contact prongs through said plug husk, means for distening the husk opening, means carried by said block for operating the distending means in timed sequence to the movement of said pull arms, fluid operated means for reciprocating said block, and means for reciprocating said nest in timed sequence to the movement of said block, said nest reciprocating means comprising a fluid cylinder mounted at the rear of said base, a pin extending from said cylinder, a second block slidably mounted on said base and actuated by said pin, and connecting rods between said second block and said nest, said distending means comprising a pair of hook members mounted for transverse sliding movement in front of said nest, a cam bar carried by said block for operating said hook members, said block having a vertical pin extending through an opening in said cam bar, said opening being elongated to provide a lost motion eflect.

8. An apparatus comprising a base, a nest mounted on said base for limited reciprocating movement, said nest being adapted to receive a plug husk of resilient material having an opening, a block mounted for reciprocating movement on said base, pull arms carried by said block and movable through a plug husk positioned in said nest for pulling contact prongs through said plug husk, means for distending the husk opening, means carried by said block for operating the distending means in timed sequence to the movement of said pull arms, fluid operated 6 means for reciprocating said block, and means for reciprocating said nest in timed sequence to the movement of said block, said nest reciprocating means comprising a fluid cylinder mounted at the rear of said base, a pin extending from said cylinder, a second block slidably mounted on said base and actuated by said pin, and

connecting rods between said second block and said nest,

said connecting rods passing through said first named block, said distending means comprising a pair of hook members mounted for transverse sliding movement in front of said nest, a cam bar carried by said first-named block for operating said hook members, said first-named block having a vertical pin extending through an opening in said cam bar, said opening being elongated to provide a lost motion efiect.

9. An apparatus comprising a base, a nest mounted on said base for limited reciprocating movement, said nest being adapted to receive a plug husk of resilient material having an opening, a block mounted for reciprocating movement on said base, pull arms carried by said block and movable through a plug husk positioned in said nest for pulling contact prongs through said plug husk, means for distending the husk opening, means carried by said block for operating the distending means in timed sequence to the movement of said pull arms, fluid operated means for reciprocating said block, and means for reciprocating said nest in timed sequence to the movement of said block, said nest reciprocating means comprising a fluid cylinder mounted at the rear of said base, a pin extending from said cylinder, a second block slidably mounted on said base and actuated by said pin, and connecting rods between said second block and said nest, said distending means comprising a pair of hook members mounted for transverse sliding movement in front of said nest, and means for locking said nest in forward position during the forward movement of said block, a cam bar carried by said block for operating said hook members, said block having a vertical pin extending through an opening in said cam bar, said opening being elongated to provide a lost motion efiect.

References Cited in the file of this patent UNITED STATES PATENTS 2,198,966 Herman Apr. 30, 1940 2,278,176 Herman Mar. 31, 1942 2,727,300 Klumpp Dec. 20, 1955 

1. AN APPARATUS COMPRISING A BASE, A NEST MOUNTED ON SAID BASE FOR LIMITED RECIPROCATING MOVEMENT, SAID NEST BEING ADAPTED TO RECEIVE A PLUG HUSK OF RESILIENT MATERIAL HAVING AN OPENING, A BLOCK MOUNTED FOR RECIPROCATING MOVEMENT ON SAID BASE, PULL ARMS CARRIED BY SAID BLOCK AND MOVABLE THROUGH A PLUG HUSK POSITIONED IN SAID NEST FOR PULLING CONTACT PRONGS THROUGH SAID PLUG HUSK, MEANS FOR DISTENDING THE HUSK OPENING, MEANS CARRIED BY SAID BLOCK FOR OPERATING THE DISTENDING MEANS IN TIMED SEQUENCE TO THE MOVEMENT OF SAID PULL ARMS, FLUID OPERATED MEANS FOR RECIPROCATING SAID BLOCK, AND MEANS FOR RECIPROCATING SAID NEST IN TIMED SEQUENCE TO THE MOVEMENT OF SAID BLOCK, SAID NEST RECIPROCATING MEANS COMPRISING A FLUID CYLINDER MOUNTED AT THE REAR OF SAID BASE, A PIN EXTENDING FROM SAID CYLINDER, A SECOND BLOCK SLIDABLY MOUNTED ON SAID BASE AND ACTUATED BY SAID PIN, AND CONNECTING RODS BETWEEN SAID SECOND BLOCK AND SAID NEST. 